Installation, Operating & Maintenance Instructions HV gate ... · Installation, Operating & Maintenance Instructions 283288EA Edition 2014-02-11 HV gate valve with pneumatic actuator

Installation, Operating & Maintenance Instructions

283288EA Edition 2014-02-11

HV gate valve with pneumatic actuator

Series 110 DN 250 – 320 mm (I. D. 10" – 12") This manual is valid for the following product ordering numbers:

11048- . E14 / 24 / 34 / 44 11050- . E14 / 24 / 34 / 44

Sample picture

Series 110

2/26 Edition 2014-02-11 283288EA

Imprint Manufacturer VAT Vakuumventile AG, CH-9469 Haag, Switzerland Website:

Phone:

Fax:

Email:

www.vatvalve.com

+41 81 771 61 61

+41 81 771 48 30

[email protected]

Publisher VAT Vakuumventile AG, CH-9469 Haag, Switzerland Editor VAT Vakuumventile AG, CH-9469 Haag, Switzerland Print VAT Vakuumventile AG, CH-9469 Haag, Switzerland Copyright © VAT Vakuumventile AG 2014 No part of these instructions may be reproduced in any way (photo-

copies, microfilms or any other reproduction processes) nor may it be manipulated with electronic systems, duplicated or distributed without written permission from VAT. Offenders are liable to pay damages.

The original VAT firmware and updated state of the art versions of the

VAT firmware are intended for use with VAT products. The VAT firmware contains a limited, time unlimited user license. The VAT firmware may not be used for purposes other than those intended nor is it permitted to make copies of the VAT firmware. In particular, it is strictly forbidden to give copies of the VAT firmware to other people.

The use of trade names, brand names, trademarks, etc. in these

Instructions does not entitle third parties to consider these names to be unprotected and to use them freely. This is in accordance with the meaning of the laws and acts covering brand names and trademarks.

http://www.vatvalve.com/

mailto:[email protected]

Series 110

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Contents

1 Description of product ........................................................................ 4 1.1 Identification of product ....................................................................................... 4 1.2 Use of product ..................................................................................................... 4 1.3 Related documents ............................................................................................. 4 1.4 Important information .......................................................................................... 4 1.5 Technical data ..................................................................................................... 4

2 Safety ................................................................................................... 5 2.1 Compulsory reading material .............................................................................. 5 2.2 Danger levels ...................................................................................................... 5 2.3 Personnel qualifications ...................................................................................... 6 2.4 Safety labels ........................................................................................................ 6

3 Design and Function ........................................................................... 7 3.1 Design ................................................................................................................. 7 3.2 Function .............................................................................................................. 7

4 Installation ........................................................................................... 8 4.1 Unpacking ........................................................................................................... 8 4.2 Installation into the system .................................................................................. 9

4.2.1 Admissible forces and bending moments ............................................. 11 4.3 Compressed air connection .............................................................................. 12 4.4 Electrical connection ......................................................................................... 13

5 Operation ........................................................................................... 14 5.1 Normal operation ............................................................................................... 14 5.2 Operation under increased temperature ........................................................... 14 5.3 Behavior in case of air pressure drop ............................................................... 14 5.4 Behavior in case of power failure ...................................................................... 14 5.5 Trouble shooting ............................................................................................... 15

6 Maintenance ...................................................................................... 16 6.1 Maintenance intervals ....................................................................................... 16 6.2 Replacement of valve gate / mechanism unit ................................................... 17 6.3 Replacement of gate seal ................................................................................. 19

7 Repairs ............................................................................................... 20

8 Dismounting and Storage ................................................................. 21 8.1 Dismounting ...................................................................................................... 22 8.2 Storage .............................................................................................................. 22

9 Packaging and Transport ................................................................. 23 9.1 Packaging ......................................................................................................... 24 9.2 Transport ........................................................................................................... 24

10 Disposal ............................................................................................. 25

11 Spare parts ........................................................................................ 26

DESCRIPTION OF PRODUCT Series 110

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1 Description of product

1.1 Identification of product

The fabrication number and order number are fixed on the product directly or by means of an identification plate.

made in Switzerland Fabrication No.:

110 . . - . . . . - . . . . / . . . . A - . . . . . .

Fabrication number Order number

1.2 Use of product

Use product for clean and dry vacuum applications only. Other applications are only allowed with the written permission of VAT.

1.3 Related documents

Product data sheet

Dimensional drawing

1.4 Important information

This symbol points to a very important statement that requires particular attention.

Example:

VAT disclaims any liability for damages resulting from inappropriate packaging.

1.5 Technical data

See product data sheet and dimensional drawing.

Series 110 SAFETY

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2 Safety

2.1 Compulsory reading material

Read this chapter prior to performing any work with or on the product. It contains important information that is significant for your own personal safety. This chapter must have been read and understood by all persons who perform any kind of work with or on the product during any stage of its serviceable life.

NOTICE Lack of knowledge

Failing to read this manual may result in property damage.

Firstly, read manual.

These Installation, Operating & Maintenance Instructions are an integral part of a comprehensive documentation belonging to a complete technical system. They must be stored together with the other documentation and accessible for anybody who is authorized to work with the system at any time.

2.2 Danger levels

DANGER High risk

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING Medium risk

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Low risk

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE Command

Indicates a hazardous situation which, if not avoided, may result in property damage.

SAFETY Series 110

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2.3 Personnel qualifications

WARNING Unqualified personnel

Inappropriate handling may cause serious injury or property damage.

Only qualified personnel are allowed to carry out the described work.

2.4 Safety labels

Label Part No. Location on valve

T-9001-155 Protective cover

Table 2-1

Series 110 DESIGN AND FUNCTION

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3 Design and Function

3.1 Design

1 Sealing surface

2 Valve body

3 Bonnet flange

4 Actuator

Figure 3-1

3.2 Function

The valve features the VATLOCK sealing technology. This means, the valve is mechani-cally locked in the closed position. In the open position, the mechanism is not locked. Leaf springs hold gate and counter-plate against the carriage with the ball retainers. The ball pairs are in the detents. For closing, the mechanism is moved forward into the closing position. The locking starts after the leaf spring stop touches the body. The ball retainers move the ball pairs out of the detents. Gate and counter-plate are spread apart. The gate seal is pressed against the sealing surface without scuffing. The arrangement of the ball pairs ensures an increase of the sealing force with vacuum on either side of the gate. During opening the movements proceed in the reverse order. See «Figure 3-2».

1 Valve gate

2 Counter-plate

3 Leaf springs

4 Ball pairs

5 Ball detents

6 Gate seal

7 Spring stop

Figure 3-2

1 2 3 4

INSTALLATION Series 110

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4 Installation




WARNING Heavy weight

Physical overstraining.

Use a crane to lift the product.

4.1 Unpacking

Make sure that the supplied products are in accordance with your order.

Inspect the quality of the supplied products visually. If it does not meet your requirements, please contact VAT immediately.

Store the original packaging material. It may be useful if products must be returned to VAT.

1. Screw eyebolts into two of the threads (1) and fasten lifting ropes to the eyebolts; see

«Figure 4-1».

Threads for eyebolts: M8, depth 14 mm Weight to carry: See product data sheet.

1 Threads for eyebolts

Figure 4-1

11

1 1

Series 110 INSTALLATION

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NOTICE Sensitive product

Product will get damaged if not handled carefully.

Handle product with care: Do not touch solid objects when lifting the product.

2. Lift valve carefully and put it down on a clean surface or mount it to a clean system.

4.2 Installation into the system

WARNING Movable parts

Human body parts may get jammed and severely injured.

Do not connect or supply electrical power and compressed air before the product is completely mounted in the system.

NOTICE Contamination

Product may get contaminated.

Always wear cleanroom gloves when handling the product.

NOTICE Inappropriate tools

Sealing surfaces may get damaged.

Do not use sharp-edged tools.

NOTICE Wrong tightening torque

Valve body and screws may get damaged.

Use tightening torque according the size of the screws.

NOTICE Too long screws

Valve body may get deformed and / or malfunctions may occur.

Make sure the length of the flange screws is suitable.


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1. Identify flange type according the fabrication number on the identification plate; see chapter «1.1 Identification of product». Example: 110 . . – P . . . / . . . = Flange type ISO-F

Valve Maximum screw-in depth «X» in mm

Nom. I.D. Flange types

mm inch C U P J T

250 10 X = 13 13 15 15 19

320 12 X = 13 13 18 18 19

C = CF-F, metric thread

U = CF-F, UNF thread

P = ISO-F

J = JIS

T = ASA-LP

Table 4-1

2. Remove protective covers from body flanges.

3. Clean sealing surfaces and seals of both flanges; see (1) and (2) according to «Figure 4-2» on page 11 .

The valve seat side is marked with the symbol «» on flange «A».

4. Put valve to the mounting position.

5. Mount the four screws (3) according to «Figure 4-2» on page 11 evenly in crosswise order until the seal touches the sealing surface.

6. Tighten all screws with the torques appropriate for their property classes.


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1 Flange A

2 Flange B

3 Screws

Figure 4-2 4.2.1 Admissible forces and bending moments

Forces from evacuating the system, from the weight of other components or from baking can lead to deformation of the valve body and to malfunction of the valve. The stress has to be relieved by suitable means, e.g. bellows sections.

The following forces or moments are admissible:

DN (nom. I.D.) Axial tensile or com-pressive force «FA»

Bending moment «M»

mm inch N lbf Nm lbf ∙ ft

250 10 3430 770 196 140

320 12 4000 900 300 220

If a combination of both forces («FA» and «M») occurs, the values mentioned above are invalid. Please contact VAT for more information.

Table 4-2

1

2

3

FA M


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4.3 Compressed air connection

WARNING Valve in open position

Risk of injury when compressed air is connected to the valve.

Connect compressed air only when: – valve is installed in the vacuum system – moving parts cannot be touched

Use clean, dry or slightly oiled air only.

Admissible air pressure range, see product data sheet.

1. Connect compressed air according to the product data sheet and dimensional drawing.


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4.4 Electrical connection

NOTICE Wrong voltage

Electrical components may get damaged.

Supply electrical components with the correct voltage.

1. Connect solenoid valve according to the product data sheet and dimensional drawing.

2. Connect position indicator according to the product data sheet and dimensional drawing.

OPERATION Series 110

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5 Operation






Do not operate before product is installed completely into the vacuum system.

5.1 Normal operation

Valve is opened and closed pneumatically.

5.2 Operation under increased temperature

Maximum allowed temperature, see product data sheet.

5.3 Behavior in case of air pressure drop

See product data sheet.

5.4 Behavior in case of power failure

See product data sheet.

Series 110 OPERATION

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5.5 Trouble shooting

Failure Check Action See

Valve does not close / open

Air pressure Connect compressed air

«4.3 Compressed air connection»

Operating pressure

Adjust operating pressure

Product data sheet

Voltage at solenoid

Connect voltage «4.4 Electrical connection»

Leak at gate Gate seal all right?

Replace seal «6.2 Replacement of valve gate / mechanism unit»

Operating pressure

Adjust operating pressure

Product data sheet

Leak at body Bonnet seal and sealing surface all right?

Clean sealing surface – if necessary, replace bonnet seal

«6.2 Replacement of valve gate / mechanism unit», steps 1 to 6

Bellows all right? Contact VAT www.vatvalve.com

Table 5-1

If you need any further information, please contact one of our service centers. You will find the addresses on our website www.vatvalve.com.



MAINTENANCE Series 110

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6 Maintenance







WARNING Hazardous components


Before starting maintenance: – disconnect compressed air supply – disconnect electrical power supply



Keep human body parts away from movable parts.

6.1 Maintenance intervals

Under clean operating conditions the valve does not require any maintenance during 200 000 cycles. After 200 000 cycles, VAT recommends replacing the mechanism unit; see chapter «6.2 Replacement of valve gate / mechanism unit».

For more information or a general overhaul please contact one of our service centers. You will find the addresses on our website www.vatvalve.com.


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6.2 Replacement of valve gate / mechanism unit

WARNING Loaded spring steel sheet


Do not put human body parts between valve gate and spring steel sheet.




NOTICE Inappropriate tools

Sealing surfaces may get damaged.

Do not use sharp-edged tools.

1. Vent chambers on either side to atmospheric pressure.

2. Open the valve.

3. Disconnect compressed air supply.

4. Disconnect electrical power supply.

5. Remove screws (1) and (2) according to «Figure 6-1» on page 18.

6. Withdraw actuator / mechanism unit carefully from body without touching the body wall; see «Figure 6-1» on page 18.

7. Remove locked ring (5) according to «Figure 6-1» on page 18.

8. Withdraw bolt (4) by pulling it downwards according to «Figure 6-1» on page 18.

MAINTENANCE Series 110

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1 Screw

2 Screw

3 Valve body

4 Bolt

5 Locked ring

6 Bonnet seal

Figure 6-1

9. Put valve gate to the horizontal position.

10. Insert new valve gate in reverse order.

11. Mount bolt (4) according to «Figure 6-1».

12. Mount locked ring (5) according to «Figure 6-1».

13. Clean sealing surface of bonnet flange.

14. Check bonnet seal – if necessary, replace it.

15. Insert actuator / mechanism unit into body without touching the body wall.

16. Mount screws (1) and screws (2) according to «Figure 6-1».

17. Connect electrical power supply.

18. Connect compressed air supply.

Valve is ready for use.

Series 110 MAINTENANCE

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6.3 Replacement of gate seal

1. Remove actuator / mechanism unit as described in «6.2 Replacement of valve gate / mechanism unit».

2. Remove gate O-ring (1) from groove; see «Figure 6-2».

Do not damage the sealing surface!

1 Gate seal

2 Valve gate

Figure 6-2

3. Check and clean sealing surface of valve seat.

4. Install new gate O-ring (1).

Press O-ring uniformly in crosswise order (diagonal) into groove.

5. Mount actuator / mechanism unit as described in section «6.2 Replacement of valve

gate / mechanism unit».

Valve is ready for use.

REPAIRS Series 110

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7 Repairs

Repairs may only be carried out by the VAT service staff. In exceptional cases, the customer is allowed to carry out the repairs, but only with the prior consent of VAT. Please contact one of our service centers. You will find the addresses on our website www.vatvalve.com.


Series 110 DISMOUNTING AND STORAGE

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8 Dismounting and Storage







WARNING Hazardous components


Before dismounting the product – disconnect compressed air supply – disconnect electrical power supply



Keep human body parts away from movable parts.




DISMOUNTING AND STORAGE Series 110

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8.1 Dismounting

NOTICE Valve in open position

Valve mechanism may get damaged if valve is in open position.

Close valve before dismounting the valve from the system.

1. Close valve.

2. Carry out the steps according to chapter «4 Installation» in reverse order. Pay attention to the safety instructions!

8.2 Storage

NOTICE Wrong storage

Inappropriate temperatures and humidity may cause damage to the product.

Valve must be stored at: – relative humidity between 10% and 70% – temperature between +10 °C and +50 °C – non-condensing environment

NOTICE Inappropriate packaging

Product may get damaged if inappropriate packaging material is used.

Always use the original packaging material and handle product with care.

1. Clean / decontaminate valve.

2. Cover all valve openings with a protective foil.

3. Pack valve appropriately by using the original packaging material.

Series 110 PACKAGING AND TRANSPORT

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9 Packaging and Transport







WARNING Harmful substances

Risk of injury in case of contact with harmful substances.

Remove harmful substances (e. g. toxic, caustic or microbiological ones) from valve before you return the valve to VAT.




When returning products to VAT, please fill out the VAT form «Declaration

of Chemical Contamination» and send it to VAT in advance. The form can be downloaded from our website www.vatvalve.com.

If products are radioactively contaminated, the VAT form «Contamination and Radiation Report» must be filled out. Please contact VAT in advance.

If products are sent to VAT in contaminated condition, VAT will carry out the decontamination procedure at the customer's expense.


PACKAGING AND TRANSPORT Series 110

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9.1 Packaging

NOTICE Valve in open position

Valve mechanism may get damaged if valve is in open position.

Make sure that the valve is closed.

4. Cover all valve openings with a protective foil.

5. Pack valve appropriately, by using the original packaging material.


9.2 Transport





Series 110 DISPOSAL

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10 Disposal

WARNING Harmful substances

Environmental pollution.

Discard products and parts according to the local regulations.

SPARE PARTS Series 110

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11 Spare parts

NOTICE Non-original spare parts

Non-original spare parts may cause damage to the product.

Use original spare parts from VAT only.

Please specify the fabrication number of the product when you place an

order for spare parts; see chapter «1.1 Identification of product». This is to ensure that the appropriate spare parts are supplied.

VAT makes a difference between spare parts that may be replaced by the customer and those that need to be replaced by the VAT service staff.

«Table 11-1» only contains spare parts that may be replaced by the customer. If you need any other spare parts, please contact one of our service centers. You will find the addresses on our website www.vatvalve.com.

Description Part No. Quantity per valve

Maintenance procedure see chapter

DN 250 Bonnet seal (Item 6 as per «Figure 6-1», page 18

On request 1 «6.2 Replacement of valve gate / mechanism unit»

Gate O-ring On request 1 «6.2 Replacement of valve gate / mechanism unit»

Mechanism, completely lubricated


DN 320 Bonnet seal (Item 6 as per «Figure 6-1», page 18


Gate O-ring On request 1 «6.2 Replacement of valve gate / mechanism unit»

Mechanism, completely lubricated


Table 11-1


Installation, Operating & Maintenance Instructions HV gate ... · Installation, Operating & Maintenance Instructions 283288EA Edition 2014-02-11 HV gate valve with pneumatic actuator

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